Method and device for collecting metallic debris

ABSTRACT

A method of and device for picking up ferrous debris off of a walking surface in a work area provides a way for workers to passively help maintain the work area and keep it free from the debris. Workers wear magnetic footwear onto the walking surface. A magnet is inserted or affixed in any recessed portion of a sole of the footwear such that a receptacle is created in the bottom of the sole to which any metallic debris that is capable of being magnetized can be attracted and retained as the workers move around the walking surface. The footwear can then be cleaned when the workers leave the work area, either by cleaning the debris from the magnet or removing some part that has retained the debris with its magnetic attraction.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation-in-part of Ser. No. 11/657325, filed Jan. 24, 2007 entitled “Foot Covering for Collecting Debris.”

BACKGROUND

The invention relates to an article of footwear such as a boot, shoe, sneaker, clog, or sandal, and more specifically to an article of footwear including a magnet for collecting ferrous debris from a walking surface.

In certain industrial environments, where machining, assembly or disassembly occurs, the walking surfaces tend to accumulate foreign objects or debris. The debris is often made up of small fasteners such as nuts, bolts, screws, nails or machining shavings or chips. The debris is a safety hazard to workers, and is attributable to puncture, cut, slip and fall injuries.

Product quality is also negatively impacted by foreign object damage, also known as (FOD). Foreign objects enter the product during assembly and can cause quality defects such as operational malfunction or complete product failure. The potential consequences of these quality defects may be loss of a customer, loss of a house by fire, or in the case of a carrier launched jet fighter, loss of the aircraft. As can be seen by the preceding examples, FOD presents a clear and present danger, and must be eliminated from industrial environments.

For various reasons, fasteners are typically made of ferrous alloys that include iron. Design constraints such as thread strength, corrosion resistance and cost, make ferrous fasteners ideal for many assembly applications. Because of their attraction to magnetic fields, the use of magnets can facilitate the collection of ferrous-material debris.

Magnetic sweeping devices, such as those disclosed in Conrad et al. U.S. Pat. No. 5,979,957, Haase et al. U.S. Pat. No. 6,142,310 and Ottens U.S. Pat. No. 6,669,024, require active interaction by a worker. A worker moves the sweeper device about a surface to collect ferrous debris as an additional activity during the workday. Because these sweeping devices require active interaction, an additional worker must be hired or a skilled worker must be utilized to sweep the walking surface for ferrous debris.

Magnetic insoles, such as those disclosed in Humphreys U.S. Pat. No. 5,233,768, Greenawalt U.S. Pat. No. 5,976,100, Qui, et al. U.S. Pat. No. 6,151,807 and Bove et al. U.S. Pat. No. 6,322,491, are utilized for therapeutic purposes. The magnets are imbedded into a sole or insole of a shoe to ensure they are in close proximity to the foot. The associated magnetic fields dilate the blood vessels, providing increased blood circulation in the foot. Because of the close proximity to the foot and insulative properties of the soles, the magnetic force does not extend to the walking surface.

What is desirable is a magnetic device for passively collecting ferrous debris from a walking surface throughout the day. The elimination of debris from the walking surface will improve worker safety, enhance product quality and improve customer satisfaction.

SUMMARY

In accordance with the present invention, an article of footwear for collecting ferrous debris from a surface is provided. A magnet can be disposed in any portion of a sole that is recessed and spaced from the surface when the sole touches the surface. In one embodiment, the magnet can be disposed in an arch portion of the sole, between the toe and heel portions. In another embodiment, the magnet can be disposed within indentations created by a tread on the sole. In both embodiments, the magnet is at least partially exposed to the surface and is spaced from the surface. The space between the magnet and the surface allows ferrous debris to accumulate, without causing a safety hazard.

A primary advantage of the present invention is the ability to easily collect ferrous objects throughout the workday, without the need for a separate sweeping activity. When all workers in a facility wear the inventive footwear, the walking surface is continuously swept of ferrous debris as the workers walk about.

These and other objects, features and advantages of the present invention will become apparent in view of the following detailed description and accompanying figures of multiple embodiments, where corresponding identifiers represent like features between the various figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view, illustrating an article of footwear according to an embodiment of the present invention;

FIG. 2 is a bottom view of the article of footwear of FIG. 1 as viewed in the direction of line A-A;

FIG. 3 is a sectional view of an embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is permanently attached to an arch surface;

FIG. 4 is a sectional view of another embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is removable to an arch surface;

FIG. 5 is a sectional view of yet another embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is permanently attached to an arch pocket, with a debris collection surface flush with an arch ceiling surface;

FIG. 6 is a sectional view of yet another embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is removable from an arch pocket, with a debris collection surface flush with an arch ceiling surface;

FIG. 7 is a sectional view of yet another an embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is permanently attached to an arch pocket, with a debris collection surface recessed below an arch ceiling surface;

FIG. 8 is a sectional view of yet another embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is removable from an arch pocket, with a debris collection surface recessed below an arch ceiling surface;

FIG. 9 is a sectional view of yet another embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is permanently attached to an arch pocket, with a debris collection surface extended beyond an arch ceiling surface; and

FIG. 10 is a sectional view of yet another embodiment of a sole of the article of footwear of FIG. 1, taken along line B-B, illustrating a magnet that is removable from an arch pocket, with a debris collection surface extended beyond an arch ceiling surface.

FIG. 11 is a perspective view of yet another embodiment of a sole of the article of footwear of FIG. 1, illustrating a magnet that can be inserted into the recesses of the sole created by a tread in both a toe and a heel portion of the sole.

FIG. 12 is a perspective view of yet another embodiment of a sole of the article of footwear of FIG. 1, illustrating a magnet that can be inserted into the recesses of the sole created by a tread when no arch is present.

FIG. 13 is a perspective view of yet another embodiment of a sole of the article of footwear of FIG. 1, illustrating multiple magnets that can be inserted into individual recesses of the sole created by tread.

DETAILED DESCRIPTION

In FIG. 1, an article of footwear 20 includes an upper portion 22 and a sole 24 attached beneath the upper portion 22. The upper portion 22 is typically made of a formable material such as leather, while the sole 24 is typically made of an insulating material such as molded urethane rubber. In the examples, the article of footwear 20 is illustrated as a work boot style, but a shoe, sneaker, clog, sandal or any other existing or created structure that can be worn on the foot would similarly benefit from the present invention.

The sole 24 is divided into three lengthwise segments; a rearward heel 26; a forward toe 28; and a central arch 30 located between the heel 26 and toe 28. An arch ceiling 32 is a surface that is raised from a walking surface S, providing an arch void 34 therebetween. Each of the heel 26 and toe 28 segments has a contact surface 36 that meets the walking surface S. In some embodiments, the arch segment 30 also contains a contact surface 36. The contact surfaces 36 may be flat or they may contain tread 37 that creates recesses 39 in the sole 24 (as illustrated in FIGS. 2 and 3) and is made of any number of raised patterns to improve traction and comfort.

Further details of the sole 24 are illustrated in FIG. 2. One or more magnets 38 are attached to the sole 24 in the arch 30 segment. A magnet 38 is permanently attached or is removable from the sole 24 to provide periodic removal for cleaning of accumulated debris D and/or replacement of the magnet 38. Although a round magnet 38 is illustrated, a magnet 38 may be rectangular, ring or polygon shaped to fit into the arch 30. The magnet 38 material may be; Hard Ferrite; Flexible Ferrite; SmCo, Samarium Cobalt; NdFeB, Neodymium Iron Boron; AlNiCo, Alnico; or any other magnet 38 material known in the art.

In FIGS. 3-4, an embodiment of an article of footwear 20 with an arch ceiling 32 mounted magnet 38 is illustrated. In the present embodiment, the magnet 38 is attached to the arch ceiling 32 with a majority of the magnet 38 exposed to the walking surface S. A collection surface 40 is raised above the walking surface S to allow debris D to accumulate on the collection surface 40 and around a periphery surface 42 without creating a tripping hazard. The collection surface 40 is raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably is raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The magnet 38 is permanently attached with an adhesive material 44 as illustrated in FIG. 3, or is removable as illustrated in FIG. 4. Removal means 46, such as tabs, clips or other fasteners, attach the magnet 38 to the arch ceiling 32, providing for periodic removal. Periodic removal of the magnet 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

In FIGS. 5-6, an embodiment of an article of footwear 20 with a pocket 48 mounted magnet 38 is illustrated. In the present embodiment, the magnet 38 is attached to a pocket 48 above the arch ceiling 32. The collection surface 40 of the magnet 38 is approximately flush with the arch ceiling 32, and only the collection surface 40 of the magnet 38 is exposed to the walking surface S. The collection surface 40 is raised above the walking surface S to allow debris D to accumulate on the collection surface 40 without creating a tripping hazard. The collection surface 40 is raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably is raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The magnet 38 is permanently attached with an adhesive material 44 as illustrated in FIG. 5, or is removable as illustrated in FIG. 6. Removal means 46, such as tabs, clips or other fasteners, attach the magnet 38 to the arch ceiling 32, providing for periodic removal. Periodic removal of the magnet 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

In FIGS. 7-8, an embodiment of an article of footwear 20 with a pocket 48 mounted magnet 38 is illustrated. In the present embodiment, the magnet 38 is attached to a pocket 48 in the arch segment 30. Please note that the arch segment 30 contacts the walking surface S in this sole 24 embodiment. The collection surface 40 and portions of the periphery surface 42 of the magnet 38 are exposed to the walking surface S. The collection surface 40 is raised above the walking surface S to allow debris D to accumulate on the collection surface 40 without creating a tripping hazard. The collection surface 40 is raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably is raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The magnet 38 is permanently attached with an adhesive material 44 as illustrated in FIG. 7, or is removable as illustrated in FIG. 8. Removal means 46, such as tabs, clips or other fasteners, attach the magnet 38 to the pocket 48, providing for periodic removal. Periodic removal of the magnet 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

In FIGS. 9-10, an embodiment of an article of footwear 20 with a pocket 48 mounted magnet 38 is illustrated. In the present embodiment, the magnet 38 is attached to a pocket 48 in the arch segment 30, and the collection surface 40 extends below the arch ceiling 32. The collection surface 40 and portions of the periphery surface 42 of the magnet 38 are exposed to the walking surface S. The collection surface 40 is raised above the walking surface S to allow debris D to accumulate on the collection surface 40 without creating a tripping hazard. The collection surface 40 is raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably is raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The magnet 38 is permanently attached with an adhesive 44 as illustrated in FIG. 9, or is removable as illustrated in FIG. 10. Removal means 46, such as tabs, clips or other fasteners, attach the magnet 38 to the pocket 48, providing for periodic removal. Periodic removal of the magnet 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

In FIG. 11, an embodiment of an article of footwear 20 with magnets 38 shaped to fit inside the recesses 39 on the sole 24 is illustrated. The recesses 39 being used with the magnets in this embodiment are created by the tread 37. The magnets 38 have collection surfaces 40 and are thin enough to be spaced above the walking surface S when they are inserted into the recesses 39. A preferred type of magnet 38 in this embodiment for insertion into the tread is the type used for refrigerator magnets. The collection surfaces 40 are raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably are raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The tread 37 is preferably thick enough to create deep recesses 39. This promotes the spacing of the collections surfaces 40 from the walking surface S. The magnets 38 are permanently or temporarily attached with an adhesive 44. Periodic removal of the magnets 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

In FIG. 12, an embodiment of an article of footwear 20 with a magnet 38 shaped to fit inside the recesses 39 on the sole 24 is illustrated. The recesses 39 being used with the magnets in this embodiment are created by the tread 37. The tread 37 in this embodiment creates recesses 39 in a continuous pattern such that one magnet 38 can be shaped into one piece for use in the recesses 39. The absence of an arch section in this embodiment also makes the one piece possible. The magnet 38 has a collection surface 40 and is thin enough to be spaced above the walking surface S when it is inserted into the recesses 39. A preferred type of magnet 38 in this embodiment for insertion into the tread is the type used for refrigerator magnets. The collection surface 40 is raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably is raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The tread 37 is preferably thick enough to create deep recesses 39. This promotes the spacing of the collections surfaces 40 from the walking surface S. The magnet 38 is permanently or temporarily attached with an adhesive 44. Periodic removal of the magnet 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

In FIG. 13, an embodiment of an article of footwear 20 with magnets 38 shaped to fit inside the recesses 39 on the sole 24 is illustrated. The recesses 39 being used with the magnets in this embodiment are created by the tread 37. The tread 37 in this embodiment creates recesses 39 in a discontinuous pattern such that multiple magnets 38 are shaped for use in the individual recesses 39. The magnets 38 have collection surfaces 40 and are thin enough to be spaced above the walking surface S when they are inserted into the recesses 39. A preferred type of magnet 38 in this embodiment for insertion into the tread is the type used for refrigerator magnets. The collection surfaces 40 are raised from 0.635 cm to 2.54 cm (0.25 inch and 1.0 inch) above the walking surface S, and preferably are raised 0.635 cm to 1.27 cm (0.25 inch and 0.5 inch) above the walking surface S. The tread 37 is preferably thick enough to create deep recesses 39. This promotes the spacing of the collections surfaces 40 from the walking surface S. The magnets 38 are permanently or temporarily attached with an adhesive 44. Periodic removal of the magnets 38 allows for cleaning of accumulated debris D and/or magnet 38 replacement.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. 

1. A method for collecting magnetic debris from a walking surface, the method comprising: placing a device that attracts and retains magnetic debris on a foot before entering a work area with magnetic debris on the walking surface; wearing the device while working in the work area, allowing the magnetic debris to be attracted to and retained by the device; and removing the device after leaving the work area.
 2. The method of claim 1 wherein the device comprises: an article of footwear having a sole, the sole having at least one indentation; and at least one magnet shaped to fit inside the indentation, the magnet having a collection surface to which magnetic material and debris are attracted.
 3. The method of claim 1 and further comprising: cleaning the device of debris when the person has left the work area.
 4. The method of claim 1 and further comprising: inserting a magnetic device that attracts and retains magnetic debris into at least one recessed portion of a sole of an article of footwear; and removing the magnetic device from the recessed portion after leaving the work area.
 5. A device for collecting magnetic debris off a walking surface comprising: an article of footwear having a sole, the sole having at least one indentation; and at least one magnet shaped to fit within the indentation, the magnet having a collection surface to which magnetic material and debris are attracted.
 6. The device of claim 5 wherein the indentation is created by a tread on the sole of the article of footwear.
 7. The device of claim 5 wherein the indentation is created by an arch in the sole of the article of footwear.
 8. The device of claim 5 wherein the indentation is sufficiently deep to allow the collection surface of the magnet to remain above the walking surface when the sole of the article of footwear is touching the walking surface.
 9. The device of claim 8 wherein the magnet is thin enough to allow its collection surface to remain above the walking surface when the sole of the article of footwear is touching the walking surface.
 10. The device of claim 9 wherein a space is created between the collection surface of the magnet and the walking surface when the sole of the article of footwear is touching the walking surface.
 11. The device of claim 10 wherein magnetic force of the magnet is at least strong enough and the collection surface of the magnet is at least close enough to the walking surface as to attract and retain magnetic material and debris lying on the walking surface.
 12. The device of claim 5 wherein there are multiple indentations on the sole of the article of footwear.
 13. The device of claim 12 wherein the indentations are in a spatial relationship that creates a continuous pattern, and wherein the magnet is shaped to fit in the continuous pattern of the indentations.
 14. The device of claim 12 wherein the indentations are in a spatial relationship that creates a noncontinuous pattern of separate indentations and wherein multiple magnet pieces are shaped to fit in the separate indentations.
 15. The device of claim 5 wherein the magnet is affixed to the sole with an adhesive.
 16. A magnetic element for use in conjunction with an article of footwear to collect magnetic debris off a walking surface, the magnetic element being shaped to fit within a recessed portion defined by a tread on a sole of the article of footwear; and the magnetic element having a magnetic force to attract and retain the magnetic debris.
 17. The magnetic element of claim 16 wherein the magnetic element has a thickness less than a depth of the recessed portion to allow the magnetic element to remain above the walking surface when the sole of the article of footwear is touching the walking surface.
 18. The magnetic element of claim 16 wherein there are multiple recessed portions on the sole of the article of footwear in a pattern that creates one continuous recessed portion, and the magnetic element is shaped into that pattern out of one piece.
 19. The magnetic element of claim 16 wherein multiple recessed portions create a noncontinuous pattern made up of separate recessed portions, and the magnetic element comprises multiple magnets to fit inside the separate recessed portions.
 20. The magnetic element of claim 16 and further comprising an adhesive for connecting the magnetic element to the sole. 